Hi all,

I modified a cheap laminator for the purpose of making PCBs via the
toner transfer method. Simple enough: reverse engineer the PCB, figure
out where to put the resistors/etc to increase temperature to ~170-180
degrees C.

It worked exceptionally well. Never before have I been able to get such
perfect toner transfers. The clothes iron method doesn't even compare.

I was able to push a few board through before one of the plastic spur
gears driving the rollers melted due to the high temperature. Luckily,
the other two gears, which are identical, are unharmed.

I need to make a replacement gear for the rollers. I'm probably going to
use plaster of Paris to make a mold using the other gears and cast some
appropriate material to make the new one. Of course, the mold will first
be properly set and baked before casting.

I'm leaning towards using aluminum, which melts at 660.32 degrees C. The
gears are small, less than 2cm in diameter. Melting a small piece of
aluminum over the mold with a blowtorch should do the trick.

Aluminum seems to be the best option. Low melting point, safe (no
dangerous fumes) when melted, easy to cast, cheap, and everywhere*.

Everywhere* but I can't seem to find anything around to melt. My unibody
MacBook Pro is not an option. Soda cans will work if melted slowly, but
they tend to produce a lot of slag, which I'd rather not deal with for
such a small job. And I don't want to have to drink 10 cans of soda to
do it.

Can anyone name a few household/cheap easily acquired things made out of
(preferably) pure aluminum that can be melted?

Any tips?
--=20
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